Rectangular secondary battery and method of manufacturing the same

ABSTRACT

A rectangular secondary battery includes a rectangular casing that contains an electrode body, a sealing plate that seals an opening of the rectangular casing, a first positive electrode tab group that is composed of a plurality of positive electrode tabs, a positive electrode terminal that is attached to the sealing plate, a second positive electrode current collector that constitutes a positive electrode current collector member that is electrically connected to the first positive electrode tab group and the positive electrode terminal, and a second insulator. The second insulator includes a base portion that is disposed between the sealing plate and the second positive electrode current collector. The first positive electrode tab group is bent and connected to the second positive electrode current collector, the region being disposed along the sealing plate. A first wall portion is disposed between the first positive electrode tab group and the rectangular casing.

TECHNICAL FIELD

The present invention relates to a rectangular secondary battery and a method of manufacturing the rectangular secondary battery.

BACKGROUND ART

Rectangular secondary batteries, such as non-aqueous electrolyte secondary batteries and the like, are used as electric power sources for driving electric automobiles (EV), hybrid electric automobiles (HEV, PHEV), and the like.

The rectangular secondary batteries each have a battery case that is composed of a bottomed rectangular casing that has an opening and a sealing plate that seals the opening. The battery case contains, as well as an electrolyte, an electrode body that is composed of a positive electrode plate, a negative electrode plate, and a separator. A positive electrode terminal and a negative electrode terminal are attached to the sealing plate. The positive electrode terminal is electrically connected to the positive electrode plate via a positive electrode current collector, and the negative electrode terminal is electrically connected to the negative electrode plate via a negative electrode current collector.

The positive electrode plate includes a positive electrode core, which is made of a metal, and a positive electrode active material mixture layer, which is formed on a surface of the positive electrode core. A positive-electrode-core exposed portion, on which the positive electrode active material mixture layer is not formed, is formed on a part of the positive electrode core. The positive electrode current collector is connected to the positive-electrode-core exposed portion. The negative electrode plate includes a negative electrode core, which is made of a metal, and a negative electrode active material mixture layer, which is formed on a surface of the negative electrode core. A negative-electrode-core exposed portion, on which the negative electrode active material mixture layer is not formed, is formed on a part of the negative electrode core. The negative electrode current collector is connected to the negative-electrode-core exposed portion.

For example, PTL 1 proposes a rectangular secondary battery that includes a rolled electrode body that has a rolled positive-electrode-core exposed portion at one end portion thereof and a rolled negative-electrode-core exposed portion at the other end portion thereof. PTL 2 proposes a rectangular secondary battery that includes an electrode body that has a positive-electrode-core exposed portion and a negative-electrode-core exposed portion at one end portion thereof.

CITATION LIST Patent Literature

PTL 1: Japanese Published Unexamined Patent Application No. 2009-032640

PTL 2: Japanese Published Unexamined Patent Application No. 2008-226625

SUMMARY OF INVENTION Technical Problem

Regarding rectangular secondary batteries used for automobiles, in particular, EVs, PHEVs, and the like, development of a rectangular secondary battery that has higher volume energy density and larger battery capacity is required. In the rectangular secondary battery disclosed in PTL 1, the inside of the battery case needs to have left and right spaces, in which the rolled positive-electrode-core exposed portion and the rolled negative-electrode-core exposed portion are disposed, and an upper space between the sealing plate and the rolled electrode body. Therefore, it is difficult to increase the volume energy density of the rectangular secondary battery. In contrast, by disposing the positive-electrode-core exposed portion and the negative-electrode-core exposed portion on the sealing plate side as in the rectangular secondary battery disclosed in PTL 2, it becomes easier to obtain a rectangular secondary battery having high volume energy density.

A main object of the present invention is to provide a rectangular secondary battery that has improved volume energy density and higher reliability.

Solution to Problem

A rectangular secondary battery according to an aspect of the present invention includes an electrode body that includes a positive electrode plate and a negative electrode plate; a rectangular casing that has an opening and contains the electrode body; a sealing plate that seals the opening; a tab that is provided on the positive electrode plate or the negative electrode plate; a tab group that is composed of a plurality of the tabs; a terminal that is electrically connected to the tab group and attached to the sealing plate; a current collector member that is electrically connected to the tab group and the terminal; and an insulator. The insulator includes a base portion that is disposed between the sealing plate and the current collector member and a first wall portion that protrudes from the base portion toward the electrode body. The tab group is disposed on the sealing plate side of the electrode body. The tab group is bent and is connected to a region of the current collector member, the region being disposed along the sealing plate. In a transversal direction of the sealing plate, the first wall portion is located nearer than a connection portion between the tab group and the current collector member to the rectangular casing. The first wall portion is disposed between the tab group and the rectangular casing.

With the structure described above, the tab group, which is provided on the positive electrode plate or the negative electrode plate, is disposed on the sealing plate side of the electrode body. The tab group is bent and connected to a region in the current collector member, the region being disposed along the sealing plate. Therefore, it is possible to easily obtain a rectangular secondary battery that has higher volume energy density. The insulator includes the base portion, which is disposed between the sealing plate and the current collector member and the first wall portion that protrudes from the base portion toward the electrode body. Because the first wall portion is disposed between the tab group and the rectangular casing, the tab group and the rectangular casing do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability. The structure described above may be applied to at least one of the positive electrode side and the negative electrode side. The electrode body may include a plurality of positive electrode plates or a plurality of negative electrode plates on each of which one or more tabs are provided, and the plurality of tabs may constitute a tab group. A plurality of tabs may be provided on one positive electrode plate or one negative electrode plate, and these tabs may constitute a tab group.

A method of manufacturing a rectangular secondary battery according to an aspect of the present invention is a method of manufacturing a rectangular secondary battery that includes an electrode body that includes a positive electrode plate and a negative electrode plate, a rectangular casing that has an opening and contains the electrode body, a sealing plate that seals the opening, a tab that is provided on the positive electrode plate or the negative electrode plate, a tab group that is composed of a plurality of the tabs, a terminal that is electrically connected to the tab group and attached to the sealing plate, a current collector member that is electrically connected to the tab group and the terminal, and an insulator. The insulator includes a base portion that is disposed between the sealing plate and the current collector member and a first wall portion that protrudes from the base portion toward the electrode body. The tab group is disposed on the sealing plate side of the electrode body. The tab group is bent and is connected to a region of the current collector member, the region being disposed along the sealing plate. In a transversal direction of the sealing plate, the first wall portion is located nearer than a connection portion between the tab group and the current collector member to the rectangular casing. The method includes a connection step of connecting the tab group to the current collector member; a placement step of placing the current collector member on the sealing plate with the base portion interposed therebetween; a bending step of bending the tab group; and a step of inserting the electrode body into the rectangular casing so that the first wall portion is placed between the tab group and the rectangular casing.

With the structure described above, the tab group, which is provided on the positive electrode plate or the negative electrode plate, is disposed on the sealing plate side of the electrode body. The tab group is bent and connected to a region in the current collector member, the region being disposed along the sealing plate. Therefore, it is possible to easily obtain a rectangular secondary battery that has higher volume energy density. The insulator includes the base portion, which is disposed between the sealing plate and the current collector member and the first wall portion that protrudes from the base portion toward the electrode body. Because the first wall portion is disposed between the tab group and the rectangular casing, the tab group and the rectangular casing do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability. Moreover, because the current collector member, to which the tab group is connected, is placed on the sealing plate with the base portion of the insulator interposed therebetween, a rectangular secondary battery having higher volume energy density can be manufactured easily. The structure described above may be applied to at least one of the positive electrode side and the negative electrode side. The electrode body may include a plurality of positive electrode plates or a plurality of negative electrode plates on each of which one or more tabs are provided, and the plurality of tabs may constitute a tab group. A plurality of tabs may be provided on one positive electrode plate or one negative electrode plate, and these tabs may constitute a tab group. Advantageous Effects of Invention

With the present invention, it is possible to provide a rectangular secondary battery that has higher volume energy density and high reliability.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a rectangular secondary battery according to an embodiment.

FIG. 2 is a sectional view of a rectangular secondary battery taken along line II-II in FIG. 1.

FIG. 3 is a plan view of a positive electrode plate according to the embodiment.

FIG. 4 is a plan view of a negative electrode plate according to the embodiment.

FIG. 5 is a plan view of an electrode body element according to the embodiment.

FIG. 6 is a perspective view of a positive electrode terminal, an outer insulator, a sealing plate, a first insulator, and a conductor.

FIG. 7 is a bottom view of the sealing plate after the components have been attached.

FIG. 8A is a sectional view taken along line VIIIA-VIIIA in FIG. 7, FIG. 8B is a sectional view taken along line VIIIB-VIIIB in FIG. 7, and FIG. 8C is a sectional view taken along line VIIIC-VIIIC in FIG. 7.

FIG. 9 is a perspective view of a deformable plate.

FIG. 10A is a perspective view of a first positive electrode current collector and a second insulator before being assembled, FIG. 10B is a perspective view of the first positive electrode current collector and the second insulator after having been assembled, and FIG. 10C is a perspective view of the first positive electrode current collector and the second insulator after having been fixed.

FIG. 11 is an enlarged view of a portion near a connection portion between the deformable plate and the first positive electrode current collector in FIG. 8A.

FIG. 12 is a perspective view of the sealing plate to which the components are attached.

FIG. 13 is a longitudinal sectional view of a portion of the sealing plate near the negative electrode terminal.

FIG. 14 illustrates a method of attaching tabs to current collector members.

FIG. 15 illustrates a step of placing a second positive electrode current collector on the sealing plate with the second insulator interposed therebetween.

FIG. 16 is a sectional view of a portion near the sealing plate taken along line XVI-XVI in FIG. 1.

FIG. 17 illustrates a surface of the sealing plate inside the battery before the components are attached.

FIG. 18 is a perspective view of an inner insulator on the negative electrode side.

FIG. 19 is a sectional view of a portion near a sealing plate of a rectangular secondary battery according to a modification taken along line XVI-XVI in FIG. 1.

FIG. 20 is an enlarged view of a portion near a first positive electrode tab group in FIG. 19.

FIG. 21 is an enlarged view of a portion near a second positive electrode tab group in FIG. 19.

DESCRIPTION OF EMBODIMENTS

The structure of a rectangular secondary battery 20 according to an embodiment will be described below. The present invention is not limited to the embodiment described below.

FIG. 1 is a perspective view of the rectangular secondary battery 20. FIG. 2 is a sectional view taken along line II-II in FIG. 1. As illustrated in FIGS. 1 and 2, the rectangular secondary battery 20 includes a battery case 100 that is composed of a rectangular casing 1, which has a bottomed angular-tube-like shape having an opening, and a sealing plate 2, which seals the opening of the rectangular casing 1. Preferably, the rectangular casing 1 and the sealing plate 2 are each made of a metal such as aluminum or an aluminum alloy. The rectangular casing 1 contains, as well as an electrolyte, a stacked electrode body 3, in which a positive electrode plate and a negative electrode plate are stacked with a separator interposed therebetween. An insulation sheet 14, which is made of a resin, is disposed between the electrode body 3 and the rectangular casing 1.

A positive electrode tab 40 and a negative electrode tab 50 are provided on an end portion of the electrode body 3 adjacent to the sealing plate 2. The positive electrode tab 40 is electrically connected to a positive electrode terminal 7 via a second positive electrode current collector 6 b and a first positive electrode current collector 6 a. The negative electrode tab 50 is electrically connected to a negative electrode terminal 9 via a second negative electrode current collector 8 b and a first negative electrode current collector 8 a. Here, the first positive electrode current collector 6 a and the second positive electrode current collector 6 b constitute a positive electrode current collector member 6. The first negative electrode current collector 8 a and the second negative electrode current collector 8 b constitute a negative electrode current collector member 8. The positive electrode current collector member 6 may be a single component. The negative electrode current collector member 8 may be a single component.

The positive electrode terminal 7 is fixed to the sealing plate 2 with an outer insulator 11 made of a resin interposed therebetween. The negative electrode terminal 9 is fixed to the sealing plate 2 with an outer insulator 13 made of a resin interposed therebetween. The positive electrode terminal 7 is preferably made of a metal, and more preferably made of aluminum or an aluminum alloy. The negative electrode terminal 9 is preferably made of a metal, and more preferably made of copper or a copper alloy.

Preferably, a circuit breaker mechanism 60, which operates when the pressure in the battery case 100 becomes a predetermined pressure or higher to block the conduction path between the positive electrode plate and the positive electrode terminal 7, is disposed in a conduction path between the positive electrode plate and the positive electrode terminal 7. A circuit breaker mechanism may be disposed in a conduction path between the negative electrode plate and the negative electrode terminal 9.

The sealing plate 2 has a gas discharge valve 17 that breaks when the pressure in the battery case 100 becomes a predetermined pressure or higher to discharge gas in the battery case 100 to the outside of the battery case 100. The operation pressure of the gas discharge valve 17 is set higher than the operation pressure of the circuit breaker mechanism 60.

The sealing plate 2 has an electrolyte injection hole 15. After injecting an electrolyte into the battery case 100 from the electrolyte injection hole 15, the electrolyte injection hole 15 is sealed with a sealing plug 16. Preferably, a blind rivet is used as the sealing plug 16.

Next, a method of manufacturing the rectangular secondary battery 20 and details of each component will be described.

[Making of Positive Electrode Plate]

A positive electrode slurry, which includes a lithium nickel cobalt manganese composite oxide as a positive electrode active material, polyvinylidene fluoride (PVdF) as a binder, a carbon material as a conductive agent, and an N-methyl-2-pyrrolidone (NMP) as a dispersion medium, is made. The positive electrode slurry is applied to both surfaces of a rectangular aluminum foil, having a thickness of 15 μm, as a positive electrode core. NMP in the positive electrode slurry is removed by drying this, thereby forming positive electrode active material mixture layers on the positive electrode core. Subsequently, the positive electrode active material mixture layers are each compressed so as to have a predetermined thickness. A positive electrode plate obtained in this way is cut into a predetermined shape.

FIG. 3 is a plan view of a positive electrode plate 4 made by using the method described above. As illustrated in FIG. 3, the positive electrode plate 4 has a body in which positive electrode active material mixture layers 4 b are formed on both surfaces of a rectangular positive electrode core 4 a. The positive electrode core 4 a protrudes from an edge of the body, and the protruding positive electrode core 4 a constitutes the positive electrode tab 40. The positive electrode tab 40 may be a part of the positive electrode core 4 a as illustrated in FIG. 3, or another member may be connected to the positive electrode core 4 a to serve as the positive electrode tab 40. Preferably, a positive electrode protection layer 4 d, which has higher electric resistance than the positive electrode active material mixture layers 4 b, is formed on a part of the positive electrode tab 40 adjacent to the positive electrode active material mixture layers 4 b.

[Making of Negative Electrode Plate]

A negative electrode slurry, which includes carbon black as a negative electrode active material, a styrene-butadiene rubber (SBR) as a binder, carboxymethylcellulose (CMC) as a thickener, and water, is made. The negative electrode slurry is applied to both surfaces of a rectangular copper foil, having a thickness of 8 μm, as a negative electrode core. Water in the positive electrode slurry is removed by drying this, thereby forming negative electrode active material mixture layers on the negative electrode core. Subsequently, the negative electrode active material mixture layers are each compressed so as to have a predetermined thickness. The negative electrode plate obtained in this way is cut into a predetermined shape.

FIG. 4 is a plan view of a negative electrode plate 5 made by using the method described above. As illustrated in FIG. 4, the negative electrode plate 5 has a body in which negative electrode active material mixture layers 5 b are formed on both surfaces of a rectangular negative electrode core 5 a. The negative electrode core 5 a protrudes from an edge of the body, and the protruding negative electrode core 5 a constitutes the negative electrode tab 50. The negative electrode tab 50 may be a part of the negative electrode core 5 a as illustrated in FIG. 4, or another member may be connected to the negative electrode core 5 a to serve as the negative electrode tab 50.

[Making of Electrode Body Element]

Fifty positive electrode plates 4 and fifty-one negative electrode plates 5 are made by using the method described above, and a stacked electrode body element (3 a, 3 b) is made by stacking these plates with rectangular separators made of polyolefin interposed therebetween. As illustrated in FIG. 5, the stacked electrode body element (3 a, 3 b) is made so that, at one end portion thereof, the positive electrode tabs 40 of the positive electrode plates 4 are stacked and the negative electrode tabs 50 of the negative electrode plates 5 are stacked. Separators are disposed on both outer surfaces of the electrode body element (3 a, 3 b), and the electrode plates and the separates can be fixed in a stacked state by using a tape or the like. Alternatively, by providing the separators with adhesive layers, the separators and the positive electrode plates 4, and the separators and the negative electrode plates 5 may be respectively bonded to each other.

Preferably, the size of each of the separators in plan view may be equal to or larger that of each of the negative electrode plates 5. The positive electrode plate 4 may be placed between two separators, the edges of the separators may be fused together, and then the positive electrode plates 4 and the negative electrode plates 5 may be stacked. An elongated separator may be used to make the electrode body element (3 a, 3 b), and the positive electrode plates 4 and the negative electrode plates 5 may be stacked while bending the elongated separator into a zig-zag shape. An elongated separator may be used, and the positive electrode plates 4 and the negative electrode plates 5 may be stacked while rolling up the elongated separator.

[Attachment of Components to Sealing Plate (Positive Electrode Side)]

Referring to FIGS. 2 and 6 to 8, a method of attaching the positive electrode terminal 7, the first positive electrode current collector 6 a, and the like to the sealing plate 2; and the structure of a portion near the positive electrode terminal 7 will be described. FIG. 6 is a perspective view of the positive electrode terminal 7, the outer insulator 11, the sealing plate 2, a first insulator 10, and a conductor 61 before being assembled. FIG. 7 is a bottom view of a surface of the sealing plate 2 inside the battery after the components have been attached. In FIG. 7, the positive electrode tab 40 and the negative electrode tab 50 are not illustrated. FIG. 8A is a sectional view of a portion near the positive electrode terminal 7 taken along line VIIIA-VIIIA in FIG. 7. FIG. 8B is a sectional view of a portion near the positive electrode terminal 7 taken along line VIIIB-VIIIB in FIG. 7. FIG. 8C is a sectional view of a portion near the positive electrode terminal 7 taken along line VIIIC-VIIIC in FIG. 7.

The outer insulator 11 is placed on the surface of the sealing plate 2 outside the battery near a positive electrode terminal attachment hole 2 a, and the first insulator 10 and the conductor 61 are placed on a surface of the sealing plate 2 inside the battery near the positive electrode terminal attachment hole 2 a. Next, an insertion portion 7 b of the positive electrode terminal 7, which is formed on one side of a flange 7 a, is inserted into each of a first terminal insertion hole 11 a of the outer insulator 11, the positive electrode terminal attachment hole 2 a of the sealing plate 2, a second terminal insertion hole 10 d of the first insulator 10, and a third terminal insertion hole 61 c of the conductor 61. Then, the tip of the insertion portion 7 b is upset on the conductor 61. Thus, the positive electrode terminal 7, the outer insulator 11, the sealing plate 2, the first insulator 10, and the conductor 61 are fixed. Because the insertion portion 7 b of the positive electrode terminal 7 is upset, an enlarged-diameter portion, which has a larger outside diameter than the third terminal insertion hole 61 c of the conductor 61, is formed at the tip the insertion portion 7 b. Preferably, the upset part of the insertion portion 7 b of the positive electrode terminal 7 and the conductor 61 are welded to each other by laser welding or the like. Preferably, the first insulator 10 and the outer insulator 11 are each made of a resin.

As illustrated in FIGS. 6 and 8, the first insulator 10 has a first insulator body 10 a that is disposed so as to face the sealing plate 2. A pair of first side walls 10 b are disposed at both end portions of the first insulator body 10 a in the longitudinal direction of the sealing plate 2. A pair of second side walls 10 c are disposed at both end portions of the first insulator body 10 a in the transversal direction of the sealing plate 2. The first insulator body 10 a has the second terminal insertion hole 10 d. First connection portions 10 e are disposed on outer surfaces of the second side walls 10 c. Preferably, the first connection portions 10 e are disposed at central portions of the second side walls 10 c in the longitudinal direction of the sealing plate 2. Second connection portions 10 f are disposed on the outer surfaces of the second side walls 10 c. Preferably, the second connection portions 10 f are disposed at end portions of the second side walls 10 c in the longitudinal direction of the sealing plate 2. A surface of the first insulator body 10 a on the sealing plate 2 side has a first groove 10 x, and a surface of the first insulator body 10 a on the conductor 61 side has a second groove 10 y. The second groove 10 y is located further outward than the first groove 10 x. The surface of the first insulator body 10 a on the sealing plate 2 side has recesses 10 g at corners thereof.

As illustrated in FIGS. 6 and 8, the conductor 61 has a conductor base 61 a, which is disposed so as to face the first insulator body 10 a, and a tubular portion 61 b, which extends from the edge of the conductor base 61 a toward the electrode body 3. The cross-sectional shape of the tubular portion 61 b parallel to the sealing plate 2 may be a circular shape or a polygonal shape. A flange 61 d is disposed at an end portion of the tubular portion 61 b on the electrode body 3 side. The tubular portion 61 b has a conductor opening 61 f at an end portion thereof on the electrode body 3 side. A pressing protrusion 61 e protrudes from a surface of the conductor base 61 a that faces the first insulator 10. The pressing protrusion 61 e presses the first insulator 10 toward the sealing plate 2. Preferably, the pressing protrusion 61 e is formed at the edge of the third terminal insertion hole 61 c or near the edge.

Next, a deformable plate 62 is placed so as to close the conductor opening 61 f of the conductor 61, and the edge of the deformable plate 62 is welded to the conductor 61 by laser welding or the like. Thus, the conductor opening 61 f of the conductor 61 is tightly sealed by the deformable plate 62. The conductor 61 and the deformable plate 62 are each preferably made of a metal, and more preferably made of aluminum or an aluminum alloy.

FIG. 9 is a perspective view of the deformable plate 62. In FIG. 9, the upper side is the electrode body 3 side, and the lower side is the sealing plate 2 side. As illustrated in FIG. 9, a stepped protrusion 62 a, which protrudes toward the electrode body 3, is formed at a central portion of the deformable plate 62. The stepped protrusion 62 a includes a first protrusion 62 a 1 and a second protrusion 62 a 2, which has a smaller outside diameter than the first protrusion 62 a 1 and which protrudes from the first protrusion 62 a 1 toward the electrode body 3. The deformable plate 62 has an annular rib 62 b, which protrudes toward the electrode body 3, at the outer edge thereof. The deformable plate 62 has an annular thin portion 62 c in a surface thereof on the electrode body 3 side. The deformable plate 62 may have any appropriate shape, as long as the deformable plate 62 can seal the conductor opening 61 f of the conductor 61.

Next, referring to FIG. 10, a method of fixing a second insulator 63 and the first positive electrode current collector 6 a will be described. In FIG. 10, a surface disposed on the electrode body 3 side in the rectangular secondary battery 20 is located at an upper position, and a surface disposed on the sealing plate 2 side is located at a lower position.

As illustrated in FIG. 10A, the first positive electrode current collector 6 a has a connection hole 6 c. The edge of the connection hole 6 c is welded to the deformable plate 62. The first positive electrode current collector 6 a has four fixing holes 6 d around the connection hole 6 c. The number of fixing hole 6 d may be one. However, preferably, the number of fixing holes 6 d is two or more. The first positive electrode current collector 6 a has displacement prevention holes 6 e around the connection hole 6 c. The number of displacement prevention hole 6 e may be one. However, preferably, the number of displacement prevention holes 6 e is at least two. Preferably, the displacement prevention holes 6 e are disposed between the fixing holes 6 d. Preferably, the fixing holes 6 d each have a small-diameter portion 6 d 1 and a large-diameter portion 6 d 2, which has a larger inside diameter than the small-diameter portion 6 d 1. Preferably, the large-diameter portion 6 d 2 is disposed nearer than the small-diameter portion 6 d 1 to the electrode body 3.

As illustrated in FIGS. 8 and 10A, the second insulator 63 has an insulator first region 63 x that is disposed so as to face the deformable plate 62, an insulator second region 63 y that is disposed so as to face the sealing plate 2, and an insulator third region 63 z that connects the insulator first region 63 x and the insulator second region 63 y. The insulator first region 63 x has an insulator first opening 63 a at the center thereof. A third wall portion 63 b is disposed at an end portion of the insulator first region 63 x in the longitudinal direction of the sealing plate 2. A third connection portion 63 d is formed on the third wall portion 63 b. Fourth wall portions 63 c are disposed at both end portions of the insulator first region 63 x in the transversal direction of the sealing plate 2. Fourth connection portions 63 e are formed on the fourth wall portions 63 c. Four fixing protrusions 63 f protrude from a surface of the insulator first region 63 x on the electrode body 3 side. Two displacement prevention protrusions 63 g protrude from the surface. Four claw portions 63 h are formed on a surface of the insulator first region 63 x on the sealing plate 2 side. The insulator second region 63 y is disposed nearer than the insulator first region 63 x to the sealing plate 2. The insulator second region 63 y has an insulator second opening 63 i at a position facing the electrolyte injection hole 15 of the sealing plate 2. An insulator annular rib 63 k, which extends toward the electrode body 3, is disposed at the edge of the insulator second opening 63 i.

As illustrated in FIG. 10B, the first positive electrode current collector 6 a is placed on the second insulator 63 so that the fixing protrusions 63 f of the second insulator 63 are placed in the fixing holes 6 d of the first positive electrode current collector 6 a and the displacement prevention protrusions 63 g of the second insulator 63 are placed in the displacement prevention holes 6 e of the first positive electrode current collector 6 a. The tips of the fixing protrusions 63 f of the second insulator 63 are deformed by thermally upsetting these tips. Thus, as illustrated in FIGS. 8C and 10C, enlarged-diameter portions 63 f 1 are formed at the tips of the fixing protrusions 63 f of the second insulator 63, and the second insulator 63 and the first positive electrode current collector 6 a are fixed.

Preferably, as illustrated in FIG. 8C, the enlarged-diameter portions 63 f 1, which are formed at the tips of the fixing protrusions 63 f of the second insulator 63, are disposed in the large-diameter portions 6 d 2 of the fixing holes 6 d.

The displacement prevention protrusions 63 g of the second insulator 63 are not thermally upset, in contrast to the fixing protrusions 63 f.

Preferably, the outside diameter of each of the fixing protrusions 63 f is larger than the outside diameter of each of the displacement prevention protrusions 63 g. Preferably, the inside diameter of each of the small-diameter portions 6 d 1 of the fixing holes 6 d of the first positive electrode current collector 6 a is larger than the inside diameter of each of the displacement prevention holes 6 e of the first positive electrode current collector 6 a.

Next, as illustrated in FIGS. 8A to 8C, the second insulator 63, to which the first positive electrode current collector 6 a has been fixed, is connected to the first insulator 10 and the conductor 61.

As illustrated in FIG. 8B, the fourth connection portions 63 e of the second insulator 63 are connected to the first connection portions 10 e of the first insulator 10. As illustrated in FIG. 8C, the claw portions 63 h of the second insulator 63 are connected to the flange 61 d of the conductor 61. Thus, the second insulator 63 is connected to each of the first insulator 10 and the conductor 61. The second insulator 63 need not be connected to both of the first insulator 10 and the conductor 61. However, preferably, the second insulator 63 is connected to at least one of the first insulator 10 and the conductor 61. Thus, it is possible to suppress application of a load to a fragile part of the first positive electrode current collector 6 a even when a strong impact or vibration is applied to the rectangular secondary battery 20. Thus, it is possible to suppress damage or breakage of a fragile part of the first positive electrode current collector 6 a.

The deformable plate 62 is welded to the first positive electrode current collector 6 a. FIG. 11 is an enlarged view of a portion near a connection portion between the deformable plate 62 and the first positive electrode current collector 6 a in FIG. 8A. As illustrated in FIG. 11, the second protrusion 62 a 2 of the deformable plate 62 is placed in the connection hole 6 c of the first positive electrode current collector 6 a. The second protrusion 62 a 2 of the deformable plate 62 and the edge of the connection hole 6 c of the first positive electrode current collector 6 a are welded to each other by laser welding or the like. The connection portion between the deformable plate 62 and the first positive electrode current collector 6 a is formed at a position corresponding to the insulator first opening 63 a of the second insulator 63.

A thin portion 6 f is formed in the first positive electrode current collector 6 a around the connection hole 6 c. An annular notch 6 g is formed in the thin portion 6 f so as to surround the connection hole 6 c. An annular connection rib 6 h is formed at the edge of the connection hole 6 c. The connection rib 6 h and the deformable plate 62 are welded to each other. The first positive electrode current collector 6 a and the deformable plate 62 may be welded in an annular shape around the entire periphery of the connection hole 6 c, or may have an unwelded part, instead of being welded in an annular shape. The first positive electrode current collector 6 a and the deformable plate 62 may be welded along the edge of the connection hole 6 c at a plurality of positons that are separated from each other.

Here, the operation of the circuit breaker mechanism 60 will be described. As the pressure in the battery case 100 increases, a central portion of the deformable plate 62 deforms so as to move toward the sealing plate 2 side. When the pressure in the battery case 100 becomes a predetermined pressure or higher, due to the deformation of the deformable plate 62, the notch 6 g of the thin portion 6 f of the first positive electrode current collector 6 a breaks. Thus, the conduction path from the positive electrode plate 4 to the positive electrode terminal 7 is cut. As described above, the circuit breaker mechanism 60 includes the first positive electrode current collector 6 a, the deformable plate 62, and the conductor 61. When the rectangular secondary battery 20 becomes overcharged and the pressure in the battery case 100 increases, the circuit breaker mechanism 60 operates to cut the conduction path from the positive electrode plate 4 to the positive electrode terminal 7, thereby preventing further overcharging. The operation pressure at which the circuit breaker mechanism 60 operates may be appropriately determined.

Before welding the deformable plate 62 and the first positive electrode current collector 6 a to each other, by supplying a gas to the inside of the conductor 61 through a terminal through-hole 7 c formed in the positive electrode terminal 7, it is possible to perform a leakage test of the welded part between the conductor 61 and the deformable plate 62. The terminal through-hole 7 c is sealed by a terminal sealing member 7 x. Preferably, the terminal sealing member 7 x is composed of a metal member 7 y and a rubber member 7 z.

FIG. 12 is a perspective view of the sealing plate 2 to which the first insulator 10, the conductor 61, the deformable plate 62, the second insulator 63, and the first positive electrode current collector 6 a are attached. As illustrated in FIG. 12, the third connection portion 63 d is formed at an end portion of the second insulator 63 in the longitudinal direction of the sealing plate 2. The second connection portions 10 f are formed at both ends of the first insulator 10 in the transversal direction of the sealing plate 2.

[Attachment of Components to Sealing Plate (Negative Electrode Side)]

Referring to FIGS. 2 and 13, a method of attaching the negative electrode terminal 9 and the first negative electrode current collector 8 a to the sealing plate 2 will be described. The outer insulator 13 is placed on a surface of the sealing plate 2 outside the battery near a negative electrode terminal attachment hole 2 b. An inner insulator 12 and the first negative electrode current collector 8 a are placed on a surface of the sealing plate 2 inside the battery near the negative electrode terminal attachment hole 2 b. Next, the negative electrode terminal 9 is inserted into each of a through-hole of the outer insulator 13, the negative electrode terminal attachment hole 2 b of the sealing plate 2, a through-hole of the inner insulator 12, and a through-hole of the first negative electrode current collector 8 a. The tip of the negative electrode terminal 9 is upset on the first negative electrode current collector 8 a. Thus, the outer insulator 13, the sealing plate 2, the inner insulator 12, and the first negative electrode current collector 8 a are fixed. Preferably, the upset part of the negative electrode terminal 9 and the first negative electrode current collector 8 a are welded to each other by laser welding or the like. Preferably, the inner insulator 12 and the outer insulator 13 are each made of a resin.

[Connection of Current Collector and Tab]

FIG. 14 illustrates a method of connecting the positive electrode tab 40 to the second positive electrode current collector 6 b, and a method of connecting the negative electrode tab 50 to the second negative electrode current collector 8 b. Two electrode body elements are made by using the methods, and the electrode body elements will be respectively referred to as the first electrode body element 3 a and the second electrode body element 3 b. The first electrode body element 3 a and the second electrode body element 3 b may have exactly the same structure or may have different structures. Here, a plurality of positive electrode tabs 40 of the first electrode body element 3 a constitute a first positive electrode tab group 40 a. A plurality of negative electrode tabs 50 of the first electrode body element 3 a constitute a first negative electrode tab group 50 a. A plurality of positive electrode tabs 40 of the second electrode body element 3 b constitute a second positive electrode tab group 40 b. A plurality of negative electrode tabs 50 of the second electrode body element 3 b constitute a second negative electrode tab group 50 b.

The second positive electrode current collector 6 b and the second negative electrode current collector 8 b are placed between the first electrode body element 3 a and the second electrode body element 3 b. Then, the first positive electrode tab group 40 a, which is composed of a plurality of positive electrode tabs 40 that are stacked and protrude from the first electrode body element 3 a, is placed on the second positive electrode current collector 6 b; and the first negative electrode tab group 50 a, which is composed of a plurality of negative electrode tabs 50 that are stacked and protrude from the first electrode body element 3 a, is placed on the second negative electrode current collector 8 b. The second positive electrode tab group 40 b, which is composed of a plurality of positive electrode tabs 40 that are stacked and protrude from the second electrode body element 3 b, is placed on the second positive electrode current collector 6 b; and the second negative electrode tab group 50 b, which is composed of a plurality of negative electrode tabs 50 that are stacked and protrude from the second electrode body element 3 b, is placed on the second negative electrode current collector 8 b. The first positive electrode tab group 40 a and the second positive electrode tab group 40 b are welded to the second positive electrode current collector 6 b, and welds 90 are formed. The first negative electrode tab group 50 a and the second negative electrode tab group 50 b are each welded to the second negative electrode current collector 8 b, and welds 90 are formed. Welding can be performed as follows.

Welding is performed by vertically clamping the stacked tabs (the first positive electrode tab group 40 a, the second positive electrode tab group 40 b, the first negative electrode tab group 50 a, and the second negative electrode tab group 50 b) and the current collectors (the second positive electrode current collector 6 b and the second negative electrode current collector 8 b) by using welding jigs. Preferably, a welding method used here is ultrasonic welding or resistance welding. The welding jigs, which are paired, are a pair of resistance welding electrodes in the case where resistance welding is performed, and a horn and an anvil in the case where ultrasonic welding is performed. The tabs (the first positive electrode tab group 40 a, the second positive electrode tab group 40 b, the first negative electrode tab group 50 a, and the second negative electrode tab group 50 b) and the current collectors (the second positive electrode current collector 6 b and the second negative electrode current collector 8 b) may be connected by laser welding.

As illustrated in FIG. 14, the second positive electrode current collector 6 b has a current collector first region 6 b 1 and a current collector second region 6 b 2. The positive electrode tab 40 is connected to the current collector first region 6 b 1. The current collector first region 6 b 1 has a current collector second opening 6 z. The current collector first region 6 b 1 and the current collector second region 6 b 2 are connected to each other via a current collector third region 6 b 3. After connecting the second positive electrode current collector 6 b to the first positive electrode current collector 6 a, the current collector second opening 6 z is placed at a position corresponding to the electrolyte injection hole 15 of the sealing plate 2. The current collector second region 6 b 2 has a current collector first opening 6 y. A current collector first recess 6 m is formed around the current collector first opening 6 y. Target holes 6 k are formed on both sides of the current collector first opening 6 y in the transversal direction of the sealing plate 2.

As illustrated in FIG. 14, the second negative electrode current collector 8 b has a current collector first region 8 b 1 and a current collector second region 8 b 2. The negative electrode tab 50 is connected to the current collector first region 8 b 1. The current collector second region 8 b 2 has a current collector first opening 8 y. A current collector first recess 8 f is formed around the current collector first opening 8 y. Target holes 8 e are formed on both sides of the current collector first opening 8 y in the transversal direction of the sealing plate 2.

[Connection of First Positive Electrode Current Collector and Second Positive Electrode Current Collector]

As illustrated in FIGS. 2, 7, 8, and other figures, the second positive electrode current collector 6 b is placed on the second insulator 63 so that a current collector protrusion 6 x of the first positive electrode current collector 6 a is located in the current collector first opening 6 y of the second positive electrode current collector 6 b. Then, the current collector protrusion 6 x of the first positive electrode current collector 6 a and the edge of the current collector first opening 6 y of the second positive electrode current collector 6 b are welded to each other by irradiation of an energy beam such as a laser beam. Thus, the first positive electrode current collector 6 a and the second positive electrode current collector 6 b are connected. Preferably, in the current collector first recess 6 m, the first positive electrode current collector 6 a and the second positive electrode current collector 6 b are welded to each other.

As illustrated in FIGS. 2 and 8, in a direction perpendicular to the sealing plate 2, the distance between the sealing plate 2 and the current collector first region 6 b 1 is smaller than the distance between the sealing plate 2 and the current collector second region 6 b 2. With such a structure, the space occupied by the current collector portion can be reduced, and the rectangular secondary battery can have higher volume energy density.

Preferably, the target holes 6 k are used as targets for image correction, when welding the first positive electrode current collector 6 a and the second positive electrode current collector 6 b by irradiation of an energy beam such as a laser beam.

As illustrated in FIG. 8A, a current collector second recess 6w is formed in a surface of the first positive electrode current collector 6 a that faces the second insulator 63 and that is on the back side of the current collector protrusion 6 x. This is preferable, because it becomes easy to form a larger weld between the first positive electrode current collector 6 a and the second positive electrode current collector 6 b. Moreover, because the current collector second recess 6w is formed, when welding the first positive electrode current collector 6 a and the second positive electrode current collector 6 b to each other, it is possible to prevent thermal damage to the second insulator 63 during welding.

[Connection of First Negative Electrode Current Collector and Second Negative Electrode Current Collector]

As illustrated in FIG. 13, the second negative electrode current collector 8 b has the current collector first region 8 b 1 and the current collector second region 8 b 2. The negative electrode tab 50 is connected to the current collector first region 8 b 1. The current collector second region 8 b 2 has the current collector first opening 8 y. The current collector first region 8 b 1 and the current collector second region 8 b 2 are connected to each other via a current collector third region 8 b 3.

As illustrated in FIG. 13, the second negative electrode current collector 8 b is placed on the inner insulator 12 so that a current collector protrusion 8 x of the first negative electrode current collector 8 a is located in the current collector first opening 8 y of the second negative electrode current collector 8 b. Then, the current collector protrusion 8 x of the first negative electrode current collector 8 a and the edge of the current collector first opening 8 y of the second negative electrode current collector 8 b are welded to each other by irradiation of an energy beam such as a laser beam. Thus, the first negative electrode current collector 8 a and the second negative electrode current collector 8 b are connected. Preferably, in the current collector first recess 8 f, the first negative electrode current collector 8 a, and the second negative electrode current collector 8 b are welded to each other. The second negative electrode current collector 8 b has the target holes 8 e, as with the second positive electrode current collector 6 b. In the direction perpendicular to the sealing plate 2, the distance between the sealing plate 2 and the current collector first region 8 b 1 is smaller than the distance between the sealing plate 2 and the current collector second region 8 b 2. The second negative electrode current collector 8 b may be connected to the negative electrode terminal 9 without using the first negative electrode current collector 8 a.

As illustrated in FIG. 13, a current collector second recess 8 w is formed in a surface of the first negative electrode current collector 8 a that faces the inner insulator 12 and that is on the back side of the current collector protrusion 8 x. This is preferable, because it becomes easy to form a larger weld between the first negative electrode current collector 8 a and the second negative electrode current collector 8 b. Moreover, because the current collector second recess 8 w is formed, when welding the first negative electrode current collector 8 a and the second negative electrode current collector 8 b to each other, it is possible to prevent thermal damage to the inner insulator 12 during welding.

The shape of each of the current collector protrusion 6 x and the current collector protrusion 8 x in plan view is preferably a non-circular shape, and preferably a rectangular shape, an elliptical shape, or an oval-track shape.

[Bending of Tab and Making of Electrode Body]

FIGS. 15A to 15C illustrate a step of placing the second positive electrode current collector 6 b, to which the first positive electrode tab group 40 a of the first electrode body element 3 a and the second positive electrode tab group 40 b of the second electrode body element 3 b are connected, on the sealing plate 2 with the second insulator 63 interposed therebetween.

As illustrated in FIG. 15A, the second insulator 63 is placed on the surface of the sealing plate 2 inside the battery. Here, the second insulator 63 has a base portion 630 a (corresponding to the insulator second region 63 y described above). A first wall portion 630 b, which extends in a direction away from the sealing plate 2, is disposed at one end portion of the base portion 630 a in the transversal direction of the sealing plate 2; and a second wall portion 630 c, which extends in the direction away from the sealing plate 2, is disposed at the other end portion of the base portion 630 a in the transversal direction of the sealing plate 2. The base portion 630 a has the insulator second opening 63 i at a position facing the electrolyte injection hole 15 of the sealing plate 2. The insulator annular rib 63 k, which extends in the direction away from the sealing plate 2, is disposed around the insulator second opening 63 i.

Next, as illustrated in FIG. 15B, the second positive electrode current collector 6 b is placed on the sealing plate 2 with the second insulator 63 interposed therebetween. The base portion 630 a of the second insulator 63 is placed between the second positive electrode current collector 6 b and the sealing plate 2. The first wall portion 630 b and the second wall portion 630 c respectively protrude further in the direction away from the sealing plate 2 than a surface of the second positive electrode current collector 6 b to which the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are connected. After entering the state shown in FIG. 15B, the second positive electrode current collector 6 b is welded to the first positive electrode current collector 6 a.

Next, as illustrated in FIG. 15C, the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are bent so that the first electrode body element 3 a and the second electrode body element 3 b are integrated. Here, the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are bent in different directions.

The first positive electrode tab group 40 a is connected to a region of the second positive electrode current collector 6 b, the region being disposed along the sealing plate 2. The tip of the first positive electrode tab group 40 a is located on the central side in the transversal direction of the sealing plate 2. The first positive electrode tab group 40 a is bent at a position near the first wall portion 630 b and connected to each of the positive electrode plates. An outer surface of the first positive electrode tab group 40 a on the first wall portion 630 b side is in contact with an inner side surface of the first wall portion 630 b (a side surface on the central side in the transversal direction of the sealing plate 2).

The second positive electrode tab group 40 b is connected to a region of the second positive electrode current collector 6 b, the region being disposed along the sealing plate 2. The tip of the second positive electrode tab group 40 b is located on the central side in the transversal direction of the sealing plate 2. The second positive electrode tab group 40 b is bent at a position near the second wall portion 630 c and connected to each of the positive electrode plates. An outer surface of the second positive electrode tab group 40 b on the second wall portion 630 c side is in contact with an inner side surface of the second wall portion 630 c (a side surface on the central side in the transversal direction of the sealing plate 2).

The outer surface of the first positive electrode tab group 40 a on the first wall portion 630 b side is in contact with the inner side surface of the first wall portion 630 b, and the outer surface of the second positive electrode tab group 40 b on the second wall portion 630 c side is in contact with the inner side surface of the second wall portion 630 c. With such a structure, the first positive electrode tab group 40 a or the second positive electrode tab group 40 b is bent in an intended shape. Accordingly, it is possible to more effectively prevent the first positive electrode tab group 40 a or the second positive electrode tab group 40 b, which are bent, from protruding outward in the transversal direction of the sealing plate 2, from being bent in an unintended shape, and from being sharply bent. If, for example, the first positive electrode tab group 40 a or the second positive electrode tab group 40 b protrudes outward in the transversal direction of the sealing plate 2, is bent in an unintended shape, or is sharply bent, the positive electrode tab 40 may break, may be damaged, or may cause an unintended short circuit. If the first positive electrode tab group 40 a or the second positive electrode tab group 40 b protrudes outward in the transversal direction of the sealing plate 2, the tab group 40 a or 40 b may make it less easy to insert the electrode body 3 into the rectangular casing 1.

Preferably, the negative electrode side has a structure similar to that of the positive electrode side. Preferably, the inner insulator 12 has a base portion that is disposed between the sealing plate 2 and the second negative electrode current collector 8 b, and wall portions that are disposed on the base portion and extend in the direction away from the sealing plate 2. Preferably, the first negative electrode tab group 50 a and the second negative electrode tab group 50 b are respectively brought into contact with inner side surfaces of the wall portions.

Preferably, the first electrode body element 3 a and the second electrode body element 3 b are integrated by using a tape or the like. Alternatively, preferably, the first electrode body element 3 a and the second electrode body element 3 b are placed in the insulation sheet 14 that has been formed into a box-like shape or a bag-like shape to be integrated. Alternatively, preferably, the first electrode body element 3 a and the second electrode body element 3 b may be fixed by using an adhesive.

[Attachment of Cover Portion]

After connecting the second positive electrode current collector 6 b to the first positive electrode current collector 6 a and connecting the second negative electrode current collector 8 b to the first negative electrode current collector 8 a, and before integrating the first electrode body element 3 a and the second electrode body element 3 b, preferably, a cover portion 80, which is made of a resin, is connected to the first insulator 10 and the second insulator 63. The cover portion 80 is not essential and may be omitted. As illustrated in FIG. 2, in the rectangular secondary battery 20, the cover portion 80 is disposed between the first positive electrode current collector 6 a and the electrode body 3. The cover portion 80 is connected to the second connection portions 10 f of the first insulator 10 and the third connection portion 63 d of the second insulator 63. Preferably, the cover portion 80 is connected to at least one of the first insulator 10 and the second insulator 63.

[Regarding Rectangular Secondary Battery 20]

FIG. 16 is a sectional view of a portion near the sealing plate 2 taken along line XVI-XVI in FIG. 1. The first positive electrode tab group 40 a and the second positive electrode tab group 40 b are each bent and are connected to portions of the second positive electrode current collector 6 b, the portions being disposed along the sealing plate 2. With such a structure, the rectangular secondary battery 20 has higher volume energy density.

The second insulator 63 as an insulator has the base portion 630 a, which is disposed between the sealing plate 2 and the second positive electrode current collector 6 b as the positive electrode current collector member, and the first wall portion 630 b, which protrudes toward the electrode body 3 from one end portion of the base portion 630 a in the transversal direction of the sealing plate 2. The first wall portion 630 b is disposed between the first positive electrode tab group 40 a and a side surface of the rectangular casing 1 near the first positive electrode tab group 40 a (a side surface on the left side in FIG. 16). Therefore, the first positive electrode tab group 40 a and the rectangular casing 1 do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability.

On the base portion 630 a of the second insulator 63 as an insulator, the second wall portion 630 c protrudes toward the electrode body 3 from the other end portion in the transversal direction of the sealing plate 2. The second wall portion 630 c is disposed between the second positive electrode tab group 40 b and a side surface of the rectangular casing 1 near the second positive electrode tab group 40 b (a side surface on the left side in FIG. 16). Therefore, the second positive electrode tab group 40 b and the rectangular casing 1 do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability.

An outer surface of the first positive electrode tab group 40 a on the first wall portion 630 b side is in contact with an inner side surface of the first wall portion 630 b. With such a structure, it is possible to suppress deformation of the first positive electrode tab group 40 a into an unintended shape. Therefore, it is possible to more effectively prevent breakage or damage of the positive electrode tabs 40 of the first positive electrode tab group 40 a. It is possible to more effectively prevent occurrence of an unexpected short circuit between positive and negative electrodes.

An outer surface of the second positive electrode tab group 40 b on the second wall portion 630 c side is in contact with an inner side surface of the second wall portion 630 c. With such a structure, it is possible to suppress deformation of the second positive electrode tab group 40 b into an unintended shape. Therefore, it is possible to more effectively prevent breakage or damage of the positive electrode tabs 40 of the second positive electrode tab group 40 b. It is possible to more effectively prevent occurrence of an unexpected short circuit between positive and negative electrodes.

As illustrated in FIG. 16, preferably, an end portion of the insulation sheet 14 on the sealing plate 2 side is located nearer than the lower end of the first wall portion 630 b to the sealing plate 2. That is, preferably, the insulation sheet 14 extends from a position between the rectangular casing 1 and the electrode body 3 to a position between the rectangular casing 1 and the first wall portion 630 b. Preferably, an end portion of the insulation sheet 14 on the sealing plate 2 side is located nearer than the lower end of the second wall portion 630 c to the sealing plate 2. That is, preferably, the insulation sheet 14 extends from a position between the rectangular casing 1 and the electrode body 3 to a position between the rectangular casing 1 and the second wall portion 630 c. Thus, the insulation sheet 14 and the first wall portion 630 b overlap in the transversal direction of the sealing plate 2, and the insulation sheet 14 and the second wall portion 630 c overlap in the transversal direction of the sealing plate 2. Therefore, it is possible to more reliably prevent the first positive electrode tab group 40 a or the second positive electrode tab group 40 b from directly contacting the rectangular casing 1. Preferably, in the transversal direction of the sealing plate 2, the thickness of the first wall portion 630 b and the thickness of the second wall portion 630 c are each larger than the thickness of the insulation sheet 14.

As illustrated in FIG. 16, in the transversal direction of the sealing plate 2, the distance between the rectangular casing 1 and the first wall portion 630 b is larger than the distance between the rectangular casing 1 and the electrode body 3. The distance between the rectangular casing 1 and the second wall portion 630 c is larger than the distance between the rectangular casing 1 and the electrode body 3 in the transversal direction of the sealing plate 2. With such a structure, it is possible to more reliably prevent the first positive electrode tab group 40 a or the second positive electrode tab group 40 b from directly contacting the rectangular casing 1.

The positive electrode current collector member 6 is composed of the first positive electrode current collector 6 a and the second positive electrode current collector 6 b, and the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are connected to the second positive electrode current collector. Therefore, it is possible to make a rectangular secondary battery having higher volume energy density by using a simpler method.

As illustrated in FIG. 17, a surface of the sealing plate 2 on the electrode body 3 side has a first recess 2 c. As illustrated in FIG. 6, a first protrusion70 protrudes from a part of the second insulator 63 facing the sealing plate 2. In the rectangular secondary battery 20, the first protrusion70 is disposed in the first recess 2 c. Thus, it is possible to suppress large displacement of the second insulator 63 with respect to the sealing plate 2 in a plane parallel to the sealing plate 2.

The shapes of the first protrusion70 and the first recess 2 c are not particularly limited. Preferably, the shape of the first protrusion70 is a circular shape, when seen in the direction perpendicular to the sealing plate 2. Preferably, the shape of the first recess 2 c is a circular shape, and more preferably an elongated circular shape, when seen in the direction perpendicular to the sealing plate 2.

The difference between the width of the first recess 2 c and the width of the first protrusion70 in the transversal direction of the sealing plate 2 is preferably 5 mm or smaller, more preferably 3 mm or smaller, and further preferably 1 mm or smaller.

Preferably, the width of the first recess 2 c in the longitudinal direction of the sealing plate 2 is larger than the width of the first recess 2 c in the transversal direction of the sealing plate 2, when seen in the direction perpendicular to the sealing plate 2.

The difference between the width of the first recess 2 c and the width of the first protrusion70 in the longitudinal direction of the sealing plate 2 is larger than the difference between the width of the first recess 2 c and the width of the first protrusion70 in the transversal direction of the sealing plate 2. With such a structure, it is possible to suppress displacement of the second insulator 63 with respect to the sealing plate 2 in the transversal direction of the sealing plate 2, and to easily attach the second insulator 63 to the sealing plate 2.

The shapes of the first protrusion70 and the first recess 2 c in plan view are each preferably a linear shape or a dot shape, and more preferably a dot shape.

Preferably, the first recess 2 c is disposed between the gas discharge valve 17 and the electrolyte injection hole 15 in the longitudinal direction of the sealing plate 2. Preferably, the second insulator 63 is connected to another component at a position nearer than the electrolyte injection hole 15 to the positive electrode terminal 7 in the longitudinal direction of the sealing plate 2. With such a structure, because the second insulator 63 is directly or indirectly connected to the sealing plate 2 at a plurality of positions that are further apart, it is possible to more effectively suppress displacement of the second insulator 63 with respect to the sealing plate 2 in a plane parallel to the sealing plate 2. In the rectangular secondary battery 20, the second insulator 63 is connected to the first insulator 10 that is fixed to the sealing plate 2. The second insulator 63 is fixed to the conductor 61 that is fixed to the sealing plate 2 with the first insulator 10 and the positive electrode terminal 7 interposed therebetween.

Preferably, the first recess 2 c is displaced to a position nearer than the center of the sealing plate 2 to an end portion of the sealing plate 2 in the transversal direction of the sealing plate 2. With such a structure, it is possible to suppress decrease of the strength of the sealing plate 2 even when the sealing plate 2 has the first recess 2 c. Therefore, the sealing plate 2 does not deform easily.

In the rectangular secondary battery 20, the second insulator 63 has the insulator first region 63 x, which is disposed between the deformable plate 62 and the first positive electrode current collector 6 a and which is fixed to the first positive electrode current collector 6 a, and the insulator second region 63 y , which is disposed on the sealing plate 2. The first protrusion70 is formed on the insulator second region of the second insulator 63. Therefore, it is possible to suppress application of a load to a fragile part of the circuit breaker mechanism 60 due to displacement of the second insulator 63 with respect to the sealing plate 2. It is possible to prevent damage to the first positive electrode tab group 40 a or the second positive electrode tab group 40 b.

Preferably, the depth of the first recess 2 c is 30% to 70% of the thickness of the sealing plate 2 around the first recess 2 c. In the transversal direction of the sealing plate 2, the distance from the center of the sealing plate 2 to the first recess 2 c is preferably 1/10 or larger, more preferably ⅛ or larger, and further preferably ⅕ or larger of the length of the sealing plate 2.

As illustrated in FIG. 17, the surface of the sealing plate 2 on the electrode body 3 side has a second recess 2 d. As illustrated in FIG. 6, a second protrusion 71 protrudes from a part of the first insulator 10 facing the sealing plate 2. In the rectangular secondary battery 20, the second protrusion 71 is disposed in the second recess 2 d. Thus, it is possible to suppress large displacement of the first insulator 10 with respect to the sealing plate 2 in a plane parallel to the sealing plate 2.

The shapes of the second protrusion 71 and the second recess 2 d are not particularly limited. Preferably, the shape of the second protrusion 71 is a circular shape, when seen in the direction perpendicular to the sealing plate 2. The shape of the second recess 2 d is preferably a circular shape, and more preferably an elongated circular shape, when seen in the direction perpendicular to the sealing plate 2.

The difference between the width of the second recess 2 d and the width of the second protrusion 71 in the transversal direction of the sealing plate 2 is preferably 5 mm or smaller, more preferably 3 mm or smaller, and further preferably 1 mm or smaller.

The shapes of the second protrusion 71 and the second recess 2 d in plan view are each preferably a linear shape or a dot shape, and more preferably a dot shape.

Preferably, the second insulator 63, which is disposed between the deformable plate 62 and the first positive electrode current collector 6 a and which is fixed to the first positive electrode current collector 6 a, is connected to the first insulator 10. In such a case, by disposing the second protrusion 71 of the first insulator 10 in the second recess 2 d of the sealing plate 2 to suppress large displacement of the first insulator 10 with respect to the sealing plate 2, it is possible to more effectively suppress application of a load to a fragile part of the circuit breaker mechanism 60.

Preferably, the second recess 2 d is disposed further outward than the positive electrode terminal attachment hole 2 a in the longitudinal direction of the sealing plate 2. With such a structure, it is possible to suppress decrease of the strength of the sealing plate 2, compared with a case where the second recess 2 d is disposed further inward than the positive electrode terminal attachment hole 2 a in the longitudinal direction of the sealing plate 2. Preferably, the second recess 2 d is disposed nearer than the center of the sealing plate 2 to an end portion of the sealing plate 2 in the transversal direction of the sealing plate 2. In a case where the first recess 2 c is formed in the sealing plate 2, preferably, the first recess 2 c is formed on one side of the center of the sealing plate 2 and the second recess 2 d is formed on the other side of the center of the sealing plate 2 in the transversal direction of the sealing plate 2.

Preferably, the depth of the second recess 2 d is 30% to 70% of the thickness of the sealing plate 2 around the second recess 2 d. In the transversal direction of the sealing plate 2, the distance from the center of the sealing plate 2 to the second recess 2 d is preferably 1/10 or larger, more preferably ⅛ or larger, and further preferably ⅕ or larger of the length of the sealing plate 2.

As illustrated in FIG. 17, the surface of the sealing plate 2 on the electrode body 3 side has a third recess 2 e. As illustrated in FIG. 18, a third protrusion 72 protrudes from a portion of the inner insulator 12, which is disposed between the sealing plate 2 and the second negative electrode current collector 8 b, the portion facing the sealing plate 2. In the rectangular secondary battery 20, the third protrusion 72 is disposed in the third recess 2 e. Thus, it is possible to suppress large displacement of the inner insulator 12 with respect to the sealing plate 2 in a plane parallel to the sealing plate 2.

The shapes of the third protrusion 72 and the third recess 2 e are not particularly limited. Preferably, the shape of the third protrusion 72 is a circular shape, when seen in the direction perpendicular to the sealing plate 2. The shape of the third recess 2 e is preferably a circular shape, and more preferably an elongated circular shape, when seen in the direction perpendicular to the sealing plate 2.

The difference between the width of the third recess 2 e and the width of the third protrusion 72 in the transversal direction of the sealing plate 2 is preferably 5 mm or smaller, more preferably 3 mm or smaller, and further preferably 1 mm or smaller.

Preferably, the width of the third recess 2 e in the longitudinal direction of the sealing plate 2 is larger than the width of the third recess 2 e in the transversal direction of the sealing plate 2, when seen in the direction perpendicular to the sealing plate 2.

Preferably, the difference between the width of the third recess 2 e and the width of the third protrusion 72 in the longitudinal direction of the sealing plate 2 is larger than the difference between the width of the third recess 2 e and the width of the third protrusion 72 in the transversal direction of the sealing plate 2. With such a structure, it is possible to suppress displacement of the inner insulator 12 relative to the sealing plate 2 in the transversal direction of the sealing plate 2, and to easily attach the inner insulator 12 to the sealing plate 2.

The shapes of the third protrusion 72 and the third recess 2 e in plan view are each preferably a linear shape or a dot shape, and more preferably a dot shape.

Preferably, the third recess 2 e is displaced to a position nearer than the center of the sealing plate 2 to an end portion of the sealing plate 2 in the transversal direction of the sealing plate 2. With such a structure, it is possible to suppress decrease of the strength of the sealing plate 2 even when the sealing plate 2 has the third recess 2 e.

Preferably, in the transversal direction of the sealing plate 2, the first recess 2 c, in which the first protrusion70 of the second insulator 63 disposed between the sealing plate 2 and the second positive electrode current collector 6 b is disposed, is located on one side of the center of the sealing plate 2; and the third recess 2 e, in which the third protrusion 72 of the inner insulator 12 disposed between the sealing plate 2 and the second negative electrode current collector 8 b is disposed, is located on the other side of the center of the sealing plate 2. With such a structure, it is possible to suppress decrease of the strength of the sealing plate 2.

[First Modification]

A rectangular secondary battery according to a first modification has a structure similar to that of the rectangular secondary battery 20 according to the embodiment described above, except that the shapes of the first positive electrode tab group 40 a and the second positive electrode tab group 40 b differ. FIG. 19 is a sectional view of a rectangular secondary battery according to the first modification, corresponding to FIG. 16. FIG. 20 is an enlarged view of a portion near the first positive electrode tab group 40 a in FIG. 19. FIG. 21 is an enlarged view of a portion near the second positive electrode tab group 40 b in FIG. 19.

The first positive electrode tab group 40 a and the second positive electrode tab group 40 b are each bent and are connected to portions of the second positive electrode current collector 6 b, the portions being disposed along the sealing plate 2. With such a structure, the rectangular secondary battery has higher volume energy density.

The second insulator 63 as an insulator has the base portion 630 a, which is disposed between the sealing plate 2 and the second positive electrode current collector 6 b as a positive electrode current collector member, and the first wall portion 630 b, which protrudes toward the electrode body 3 from one end portion of the base portion 630 a in the transversal direction of the sealing plate 2. The first wall portion 630 b is disposed between the first positive electrode tab group 40 a and the rectangular casing 1. Therefore, the first positive electrode tab group 40 a and the rectangular casing 1 do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability.

On the base portion 630 a of the second insulator 63 as an insulator, the second wall portion 630 c protrudes toward the electrode body 3 from the other end portion in the transversal direction of the sealing plate 2. The second wall portion 630 c is disposed between the second positive electrode tab group 40 b and the rectangular casing 1. Therefore, the second positive electrode tab group 40 b and the rectangular casing 1 do not directly contact each other easily. Thus, the rectangular secondary battery has higher reliability.

The positive electrode current collector member 6 is composed of the first positive electrode current collector 6 a and the second positive electrode current collector 6 b, and the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are connected to the second positive electrode current collector. Therefore, it is possible to make a rectangular secondary battery having higher volume energy density by using a simpler method.

As illustrated in FIG. 20, the first positive electrode tab group 40 a has a first connection region 500, which is disposed on the second positive electrode current collector 6 b, and a first bent region 501, which extends from an end portion of the first connection region 500 on the first wall portion 630 b side toward the electrode body 3 and which is bent so as to bulge toward the first wall portion 630 b. A surface of the first positive electrode tab group 40 a on the rectangular casing 1 side has a first recessed region 502, which is located on the electrode body 3 side of the first bent region 501 and recessed toward the center of the sealing plate 2 (rightward in FIG. 20) in the transversal direction of the sealing plate 2.

As illustrated in FIG. 21, the second positive electrode tab group 40 b has a second connection region 503, which is disposed on the second positive electrode current collector 6 b, and a second bent region 504, which extends from an end portion of the second connection region 503 on the second wall portion 630 c side toward the electrode body 3 and which is bent so as to bulge toward the second wall portion 630 c. A surface of the second positive electrode tab group 40 b on the rectangular casing 1 side has a second recessed region 505, which is located on the electrode body 3 side of the second bent region 504 and recessed toward the center of the sealing plate 2 (leftward in FIG. 21) in the transversal direction of the sealing plate 2.

Preferably, D2≥D1 is satisfied, where, in the transversal direction of the sealing plate 2 (in the left-right direction in FIG. 19), D1 is the distance between a part of the first bent region 501 that is located nearest to the rectangular casing 1 and a part of the second bent region 504 that is located nearest to the rectangular casing 1, and D2 is the distance between the first wall portion 630 b and the second wall portion 630 c. With such a structure, it is possible to more reliably prevent the first positive electrode tab group 40 a or the second positive electrode tab group 40 b from directly contacting the rectangular casing 1.

An outer surface of the first bent region 501 may be in contact with the first wall portion 630 b. An outer surface of the second bent region 504 may be in contact with the second wall portion 630 c. With such a structure, it is possible to more effectively suppress deformation of the first positive electrode tab group 40 a or the second positive electrode tab group 40 b into an unintended shape. Therefore, it is possible to more effectively prevent breakage or damage of the positive electrode tabs 40 that constitute the first positive electrode tab group 40 a or the second positive electrode tab group 40 b. It is possible to effectively prevent occurrence of an unexpected short circuit between positive and negative electrodes.

In the rectangular secondary battery 20 according to the embodiment described above, the second insulator 63 has the base portion 630 a disposed between the sealing plate 2 and the second positive electrode current collector 6 b, the first wall portion 630 b, and the second wall portion 630 . Instead of providing the second insulator 63 with the base portion and the wall portions, the first insulator 10 may have a base portion disposed between the sealing plate 2 and the second positive electrode current collector 6 b, and wall portions that extend from the base portion toward the electrode body 3.

In the rectangular secondary battery 20 according to the embodiment described above, the first wall portion 630 b and the second wall portion 630 c are disposed on the base portion 630 a. However, only one of the first wall portion 630 b and the second wall portion 630 c may be disposed on the base portion 630 a. Preferably, both of the first wall portion 630 b and the second wall portion 630 c are disposed on the base portion 630 a.

In the rectangular secondary battery 20 according to the embodiment described above, the plurality of positive electrode tabs 40 are divided into the first positive electrode tab group 40 a and the second positive electrode tab group 40 b. However, the plurality of positive electrode tabs 40 may constitute a single tab group. Preferably, the positive electrode tabs 40 are divided into the first positive electrode tab group 40 a and the second positive electrode tab group 40 b.

The rectangular secondary battery 20 according to the embodiment described above has the circuit breaker mechanism 60. However, the circuit breaker mechanism 60 may be omitted. In a case where the circuit breaker mechanism 60 is omitted, the positive electrode side of the rectangular secondary battery 20 may have a structure similar to that of the negative electrode side.

In the rectangular secondary battery 20 according to the embodiment described above, the positive electrode current collector member 6 is composed of two components, which are the first positive electrode current collector 6 a and the second positive electrode current collector 6 b. However, the positive electrode current collector member 6 may be a single component. In the rectangular secondary battery 20 according to the embodiment described above, the negative electrode current collector member 8 is composed of two components, which are the first negative electrode current collector 8 a and the second negative electrode current collector 8 b. However, the negative electrode current collector member 8 may be a single component.

In the rectangular secondary battery 20 according to the embodiment described above, the first positive electrode tab group 40 a and the second positive electrode tab group 40 b are bent in different directions, and the first negative electrode tab group 50 a and the second negative electrode tab group 50 b are bent in different directions. However, this is not a limitation. The first positive electrode tab group 40 a and the second positive electrode tab group 40 b may be bent in the same direction, and the first negative electrode tab group 50 a and the second negative electrode tab group 50 b may be bent in the same direction.

In the rectangular secondary battery 20 according to the embodiment described above, the positive electrode terminal 7 and the negative electrode terminal 9 are insulated from the sealing plate 2. However, one of the positive electrode terminal 7 and the negative electrode terminal 9 may be electrically connected to the sealing plate 2.

Preferably, the gas discharge valve 17 of the sealing plate 2 is a thin portion of the sealing plate 2. The thin portion as the gas discharge valve 17 can be formed, for example, by press forming. A through-hole may be formed in the sealing plate 2, the through-hole may be closed with a thin valve body, and the valve body may be welded to the sealing plate 2.

<Others>

Preferably, a breakable portion that breaks when the deformable plate deforms is a fragile part of a current collector member, a connection portion between a current collector member and the deformable plate, or a fragile part of the deformable plate. Preferably, the fragile part is a thin portion, a notch, or the like.

Preferably, the first insulator, the second insulator, and the cover portion are each made of a resin. Examples of the resin include polypropylene, polyethylene, perfluoroalkoxyalkane (PFA), polytetrafluoroethylene (PTFE), and ethylene-tetrafluoroethylene copolymer (ETFE).

In the embodiment described above, the electrode body 3 is composed of two electrode body elements 3 a and 3 b. However, this is not a limitation. The electrode body 3 may be a single stacked electrode body. The electrode body 3 may be a single rolled electrode body in which an elongated positive electrode plate and an elongated negative electrode plate are rolled with a separator interposed therebetween. Each of the two electrode body elements 3 a and 3 b is not limited to a stacked electrode body and may be a rolled electrode body in which an elongated positive electrode plate and an elongated negative electrode plate are rolled with a separator interposed therebetween.

In a case where the electrode body is a stacked electrode body that has a plurality of positive electrode plates and a plurality of negative electrode plates, or, in a case where the electrode body is a rolled electrode body and the roll axis is disposed so as to be perpendicular to the sealing plate, preferably, an end portion of the positive electrode plate and an end portion of the negative electrode plate are located on the sealing plate side in the electrode body. With such a structure, in a case where the sealing plate has an electrolyte injection hole, ease of injection of an electrolyte into the electrode body is improved. In such a case, preferably, an end portion of the separator on the sealing plate side protrudes further toward the sealing plate 2 than an end portion of the negative electrode active material mixture layer of the negative electrode plate on the sealing plate side. In the electrode body, preferably, an end portion of the separator on the sealing plate side protrudes further toward the sealing plate than an end portion of the positive electrode active material mixture layer of the positive electrode plate on the sealing plate side. Preferably, the positive electrode plate and the separator are bonded via an adhesive layer, and the negative electrode plate and the separator are bonded via an adhesive layer. With such a structure, it is possible to reliably prevent the positive electrode active material mixture layer and the negative electrode active material mixture layer from contacting the second insulator, and the positive electrode active material mixture layer or the negative electrode active material mixture layer from being damaged.

REFERENCE SIGNS LIST

20 . . . rectangular secondary battery 1 . . . rectangular casing 2 . . . sealing plate 2 a . . . positive electrode terminal attachment hole 2 b . . . negative electrode terminal attachment hole 2 c . . . first recess 2 d . . . second recess 2 e . . . third recess 100 . . . battery case 3 . . . electrode body 3 a . . . first electrode body element 3 b . . . second electrode body element 4 . . . positive electrode plate 4 a . . . positive electrode core 4 b . . . positive electrode active material mixture layer 4 d . . . positive electrode protection layer 40 . . . positive electrode tab 40 a . . . first positive electrode tab group 40 b . . . second positive electrode tab group 500 . . . first connection region 501 . . . first bent region 502 . . . first recessed region 503 . . . second connection region 504 . . . second bent region 505 . . . second recessed region 5 . . . negative electrode plate 5 a . . . negative electrode core 5 b . . . negative electrode active material mixture layer 50 . . . negative electrode tab 50 a . . . first negative electrode tab group 50 b . . . second negative electrode tab group 6 . . . positive electrode current collector member 6 a . . . first positive electrode current collector 6 c . . . connection hole 6 d . . . fixing hole 6 d 1 . . . small-diameter portion 6 d 2 . . . large-diameter portion 6 e . . . displacement prevention hole 6 f . . . thin portion 6 g . . . notch 6 h . . . connection rib 6 x . . . current collector protrusion 6 w . . . current collector second recess 6 b . . . second positive electrode current collector 6 b 1 . . . current collector first region 6 b 2 . . . current collector second region 6 b 3 . . . current collector third region 6 k . . . target hole 6 m . . . current collector first recess 6 y . . . current collector first opening 6 z . . . current collector second opening 7 . . . positive electrode terminal 7 a . . . flange 7 b . . . insertion portion 7 c . . . terminal through-hole 7 x . . . terminal sealing member 7 y . . . metal member 7 z . . . rubber member 8 . . . negative electrode current collector member 8 a . . . first negative electrode current collector 8 x . . . current collector protrusion 8 w . . . current collector second recess 8 b . . . second negative electrode current collector 8 b 1 . . . current collector first region 8 b 2 . . . current collector second region 8 b 3 . . . current collector third region 8 e . . . target hole 8 f . . . current collector first recess 8 y . . . current collector first opening 9 . . . negative electrode terminal 10 . . . first insulator 10 a . . . first insulator body 10 b . . . first side wall 10 c . . . second side wall 10 d . . . second terminal insertion hole 10 e . . . first connection portion 10 f . . . second connection portion 10 g . . . recess 10 x . . . first groove 10 y . . . second groove 11 . . . outer insulator 11 a . . . first terminal insertion hole 12 . . . inner insulator 13 . . . outer insulator 14 . . . insulation sheet 15 . . . electrolyte injection hole 16 . . . sealing plug 17 . . . gas discharge valve 60 . . . circuit breaker mechanism 61 . . . conductor 61 a . . . conductor base portion 61 b . . . tubular portion 61 c . . . third terminal insertion hole 61 d . . . flange 61 e . . . pressing protrusion 61 f . . . conductor opening 62 . . . deformable plate 62 a . . . stepped protrusion 62 a 1 . . . first protrusion 62 a 2 . . . second protrusion 62 b . . . annular rib 62 c . . . annular thin portion 63 . . . second insulator 63 x . . . insulator first region 63 a . . . insulator first opening 63 b . . . third wall portion 63 c . . . fourth wall portion 63 d . . . third connection portion 63 e . . . fourth connection portion 63 f . . . fixing protrusion 63 f 1 . . . enlarged-diameter portion 63 g . . . displacement prevention protrusion 63 h . . . claw portion 63 y . . . insulator second region 63 i . . . insulator second opening 63 k . . . insulator annular rib 630 a . . . base portion 630 b . . . first wall portion 630 c . . . second wall portion 63 z . . . insulator third region 70 . . . first protrusion 71 . . . second protrusion 72 . . . third protrusion 80 . . . cover portion 90 . . . weld 

1. A rectangular secondary battery comprising: an electrode body that includes a positive electrode plate and a negative electrode plate; a rectangular casing that has an opening and contains the electrode body; a sealing plate that seals the opening; a tab that is provided on the positive electrode plate or the negative electrode plate; a tab group that is composed of a plurality of the tabs; a terminal that is electrically connected to the tab group and attached to the sealing plate; a current collector member that is electrically connected to the tab group and the terminal; and an insulator, wherein the insulator includes a base portion that is disposed between the sealing plate and the current collector member and a first wall portion that protrudes from the base portion toward the electrode body, wherein the tab group is disposed on the sealing plate side of the electrode body, wherein the tab group is bent and is connected to a region of the current collector member, the region being disposed along the sealing plate, wherein, in a transversal direction of the sealing plate, the first wall portion is located nearer than a connection portion between the tab group and the current collector member to the rectangular casing, and wherein the first wall portion is disposed between the tab group and the rectangular casing.
 2. The rectangular secondary battery according to claim 1, wherein the tab group includes a first connection region disposed on the current collector member and a first bent region that extends from an end portion of the first connection region on the first wall portion side toward the electrode body and that is bent so as to bulge toward the first wall portion, wherein a surface of the tab group on the rectangular casing side has a first recessed region that is located on the electrode body side of the first bent region and recessed toward a center of the sealing plate in the transversal direction of the sealing plate, and wherein the first wall portion is located between a part of the first bent region nearest to the rectangular casing and the rectangular casing.
 3. The rectangular secondary battery according to claim 2, wherein the insulator includes a second wall portion that protrudes from the base portion toward the electrode body, wherein the electrode body includes a first tab group and a second tab group, wherein the tab group is the first tab group, wherein the second tab group includes a second connection region disposed on the current collector member and a second bent region that extends from an end portion of the second connection region on the second wall portion side toward the electrode body and that is bent so as to bulge toward the second wall portion, wherein a surface of the tab group on the rectangular casing side has a second recessed region that is located on the electrode body side of the second bent region and recessed toward the center of the sealing plate in the transversal direction of the sealing plate, and wherein the second wall portion is located between a part of the second bent region nearest to the rectangular casing and the rectangular casing.
 4. The rectangular secondary battery according to claim 3, wherein D2≥D1 is satisfied, where, in the transversal direction of the sealing plate, D1 is a distance between a part of the first bent region located nearest to the rectangular casing and a part of the second bent region located nearest to the rectangular casing, and D2 is a distance between the first wall portion and the second wall portion.
 5. The rectangular secondary battery according to claim 1, wherein an outer surface the tab group is in contact with an inner side surface of the first wall portion.
 6. The rectangular secondary battery according to claim 1, wherein, in the transversal direction of the sealing plate, a distance between the rectangular casing and the first wall portion is larger than a distance between the rectangular casing and the electrode body.
 7. The rectangular secondary battery according to claim 1, wherein the current collector member includes a first current collector and a second current collector, wherein the first current collector and the second current collector are welded to each other, and wherein the tab group is connected to the second current collector.
 8. The rectangular secondary battery according to claim 1, wherein an insulation sheet is disposed between the electrode body and the rectangular casing, and wherein the insulation sheet extends to a position between the first wall portion and the rectangular casing.
 9. A method of manufacturing a rectangular secondary battery that includes an electrode body that includes a positive electrode plate and a negative electrode plate, a rectangular casing that has an opening and contains the electrode body, a sealing plate that seals the opening, a tab that is provided on the positive electrode plate or the negative electrode plate, a tab group that is composed of a plurality of the tabs, a terminal that is electrically connected to the tab group and attached to the sealing plate, a current collector member that is electrically connected to the tab group and the terminal, and an insulator wherein the insulator includes a base portion that is disposed between the sealing plate and the current collector member and a first wall portion that protrudes from the base portion toward the electrode body, wherein the tab group is disposed on the sealing plate side of the electrode body, wherein the tab group is bent and is connected to a region of the current collector member, the region being disposed along the sealing plate, and wherein, in a transversal direction of the sealing plate, the first wall portion is located nearer than a connection portion between the tab group and the current collector member to the rectangular casing, the method comprising: a connection step of connecting the tab group to the current collector member; a placement step of placing the current collector member on the sealing plate with the base portion interposed therebetween; a bending step of bending the tab group; and a step of inserting the electrode body into the rectangular casing so that the first wall portion is placed between the tab group and the rectangular casing.
 10. The method of manufacturing the rectangular secondary battery according to claim 9, wherein the current collector member includes a first current collector and a second current collector, wherein the tab group is connected to the second current collector in the connection step, and wherein the method includes a step of connecting the first current collector and the second current collector after the connection step.
 11. The method of manufacturing the rectangular secondary battery according to claim 9, comprising: a step of making a first electrode body element that includes the positive electrode plate and the negative electrode plate and a second electrode body element that includes the positive electrode plate and the negative electrode plate; and a step of integrating the first electrode body element and the second electrode body element into the electrode body, wherein the insulator includes a second wall portion that protrudes from the base portion toward the electrode body, wherein the tab group includes a first tab group and a second tab group, wherein the first tab group is connected to the first electrode body element, wherein the second tab group is connected to the second electrode body element, wherein the first tab group includes a first connection region disposed on the current collector member and a first bent region that extends from an end portion of the first connection region on the first wall portion side toward the electrode body and that is bent so as to bulge toward the first wall portion, wherein a surface of the first tab group on the rectangular casing side has a first recessed region that is located on the electrode body side of the first bent region and recessed toward a center of the sealing plate in the transversal direction of the sealing plate, wherein the first wall portion is located between a part of the first bent region nearest to the rectangular casing and the rectangular casing, wherein the second tab group includes a second connection region disposed on the current collector member and a second bent region that extends from an end portion of the second connection region on the second wall portion side toward the electrode body and that is bent so as to bulge toward the second wall portion, wherein a surface of the tab group on the rectangular casing side has a second recessed region that is located on the electrode body side of the second bent region and recessed toward the center of the sealing plate in the transversal direction of the sealing plate, and wherein the second wall portion is located between a part of the second bent region nearest to the rectangular casing and the rectangular casing.
 12. The method of manufacturing the rectangular secondary battery according to claim 9, wherein an outer surface the tab group is brought into contact with an inner side surface of the first wall portion in the bending step. 